of cincinnati



Patented Mar. 17,1931

UNITED STATES PATENT OFFICE HOW'ARD C. BYLAND AND FRANK L. ORMESHER, OFCINCINNATI, OHIO. ASSIGNORS TO CEMROC, INC, OF CINCINNATI, OHIO, ACORPORATION OF OHIO PROCESS OF MANUFACTURING BUILDING UNITS No Drawing.

Our invention relates to a process of manufacturing a building unit.

It is the object of our invention to provide a process of forming aplastic building unit 5 that will immediately set in its proper form,that will have high resistance to moisture absorption and greatstrength, and can be air dried within the minimum time so that it may bequickly used after having been formed.

Particularly,it is the object of our invention to be able to employconcrete, or cement combined with various kinds and types of aggregates,by this process of manufacturing, by forming the material out ofconcrete, or out of a combination of cement and other ingredients, underpressure, and at the same time provide a building unit that will havehigh resistance to moisture and adequate strength, which have beenqualities not heretofore existent in molded concrete products, or thosein which cement has been combined with Various other ingredients.

The invention consists in subjecting a 5 mixture of concrete, or amixture of cement and other ingredients to great pressure in a smallarea, by first pounding or tamping the material, or by first pounding ortamping the material, and then subjecting it to pressure,

30 or by pressure alone, therebythoroughly dispensing it in a mold andthen subsequently condensing it *by either pounding and tamping,pounding and tamping and then pressure, or by pressure alone.

For instance, it has been found that by use of a tamper of 700 pounds inweight dropping a distance of 18", that a body of concrete orcombination of cement and various kinds and types of ingredients havingapproximately the square surface of an ordinary brick, which isapproximately 4 x 8", or a square surface of 32", will be compressedapproximately and brought to the usual brick thickness, whichisapproximately 2 4". A pounding, tamping, or striking pressure ofapproximately 1000 pounds distributed over approximately a dozen brickunits will be found to be satisfactory. The square dimensions ofeach ofApplication filed. September 15, 1928. Serial No. 306,286.

tamping, or striking blow subsequent pressure which may vary any amountbut which is preferred to have approximately a 75 ton pressure, althoughas low as 8 or 10 tons have been found to be satisfactory for some typesof unit. The application of the additional pressure as indicated up toas high as 7 5 tons will cause a reduction in the thickness of the unitof about five-eighths of an inch.

It has been found, in the operation of machines practicing this process,the variations in the mixture of the aggregates forming the concrete, orthe aggregates combined with cement and other ingredients, will beaccommodated so that auniform product will be assured, which is acondition very difficult to otherwise control.

Thus, the thickness of the unit before applying the pounding, tamping,or striking, is usually two and three-fourths of an inch in depth in themold. But if pressure is to be subsequently added after the tampingoperation, or if pressure alone isto be applied, the unit should beapproximately two and sev en-eights of an inch in depth in the mold. Theresulting applicationof the forcesindicated above will bring the productto a thickness of approximately two andone-fourth of an inch. It ispreferred to usethe combination of the tamper and then the pressure.

In addition to the foregoing, in order to improve the rapidity withwhich the product sets, and the water proofing qualities of the product,we add into the aggregate composing the concrete, or combined withcement and other ingredients, ammonium stearate and calcium chloride andother ingredients,

or stearic acid and calcium chloride and other ingredients respectivelyfor the purpose of water proofing and acceleration of the setting.

Stearic acid further acts as a lubricant and facilitates thedistribution of the material in the mold under any type of pressure, andits extraction when stripped from the mold.

The exact proportions of such materials are more fully set forth inapplications Serial Nos. 272,853, 272,854, 293,798, and 293,791 nowpending in the United States Patent Ofiice.

Vi e further find that it is desirable to add coloring material, such asmineral oxide, and that, when the method of manufacturing these buildingunits is followed, the addition of mineral oxide does not weaken orchange the absorption qualities of the resulting product. Nor will themineral oxide fade because of the acceleration of the setting of thematerial which is facilitated by its high pressure, homogeneouscharacter, and rapid setting due to acceleration.

This is also becaus the combination of stearic acid, calcium chloride,and other ingredients immediately and properly set up the cement so thatit will have no reaction on the mineral oxide. The combination ofstearic acid, calcium chloride, and other ingredients also hermeticallyseals the voids in the product, thus preventing penetration by moisture,air and chemicals which prevents alteration of the color of the finishedproduct. By reason of the fact that the combination of stcaric acid,calcium chloride and other ingredients lubricates the material, it makesa denser unit, thereby causing a mechanical sealing of the voids. lVhileat the same time it generates heat in the concrete, or cement combinedwith various kinds and types of aggregates and other ingredients, andthus keeps it at a uniform temperature so that the cement will have theproper colloidal action.

lVhile varying types of aggregate for the concrete may be employed, itis preferred to employ a typical combination of six feet of sandcomprised of three feet of clean fine sharp sand and three feet ofcoarse sand or gravel for every 94 pounds of cement. Where no coloringis used this aggregate is mixed thoroughly dry for approximately twominutes. It is then dampened by a line spray di rected onto thematerials at an angle of approximately 45 degrees, while the concretemixer is running thus agitating the material. From 4 to 8 gallons ofwater is added in this manner, the amount of water varying accord ing tothe condition of the aggregates at the time they are placed into theconcrete mixer. lVhile the lto 8 gallons of water is being added to themixture, the mixer is kept running for approximately 3 to 5 minutes. Thematerial is then fed from the mixer into the molds subjected topressure, and removed for drying. Immediately following the mixing dry,approximately a gallon of water is added by means of the sprayingprocess, then there is added the proper amount of ammonium stearate, andcalcium chloride, and other ingredients, or the proper amount of stearicacid, and calcium chloride, and other ingredients. If the finishedproduct is to be colored, the aggregate should be mixed thoroughly dryfor approximately two minutes. It is then dampened by a line spraydirected on to the materials in the usual concrete mixer, at an angle ofapproximately 45 degrees. Approximately one gallon of water should beapplied at this time during the mixing process. Immediately followingthis mixing there is added about four liquid gallons composed ofappropriate parts of water, mineral oxide, and the appropriateproportions of ammonium stearate and cal cium chloride, and otheringredients, or appropriate proportions of stearic acid, calciumchloride, and other ingredients, depending on the temperature of theoperation, and the temperature of the material when it is being formedand set. In addition to the two minutes of dry mixing, this materialshould be mixed an additional 3 to 5 minutes during the spraying anddampening process.

The consistency of the aggregates should be such that when subjected toany of the above indicated processes of tamping, tamping and pressure,or pressure alone, no excess water or moisture escapes from the product.

The product is allowed to remain at an even temperature twenty fourhours after being formed, but thereafter it can be removed from thebuilding where the uniform temperature is maintained and stacked in theoutside yards. It is ready for use one week after having been so formed.

It will be understood that we desire to comprehend within our inventionsuch modifications as may be necessary to adapt it to varying conditionsand uses.

Having thus fully described our invention, what we claim as new anddesire to secure by Letters Patent, is

1. In a process of manufacturing a building material, pouring concrete,ammonium stearate and calcium chloride into a mold, subjecting theconcrete to a blow to reduce it appreciably in thicknessand immediatelywithdrawing the molded product from the mold and allowing it to dry inthe air.

2. In a process of manufacturing a building unit, pouring concrete intoa mold, subjecting the concrete to a heavy blow to reduce its depth,subsequently subjecting it to a heavier pressure to still further reduceit in depth, holding the pressure an appreciable interval and removingthe molded products from the mold.

3. In a process of manufacturing a building unit, pouring concrete intoa mold, subjecting the concrete to a heavy blow to reduce its depth,subsequently subjecting it to a heavier pressure to still further reduceit in depth, holding the pressure an appreciable interval and removingthe molded products from the mold, and drying in the air.

4. In a process of manufacturing a building unit, pouring concrete intoa mold and subjecting the concrete to approximately seventy-five tonspressure, relieving the pressure and stripping the concrete from themold in molded form and allowing it to dry in the air.

5. In a process of manufacturing a building unit, mixing concrete,ammonium stearate and calcium chloride, adding to the mixture mineraloxide coloring material, pouring in plastic form into a mold, subjectinvto a blow of approximately 1000 pounds, siibjecting to subsequentpressure of approximately seventy-five tons, relieving the pressure, andstripping the molded product from the mold and allowing it to dry in theair.

6. In a process of manufacturing a build ing unit, mixing concrete,ammonium stearate and calcium chloride, pouring in plastic form into amold, subjecting to a blow of approximately 1000 pounds, subsequentlysubjecting the concrete to a pressure of approximately seventy-fivetons, relieving the pressure, stripping the molded product from themold, and allowing it to dry in the air.

7. In a process of manufacturing a building unit, mixing concrete,ammonium stearate and calcium chloride, pouring in plastic form into amold, subjecting the plastic mass to a blow between 750 to 1000 poundsapprox imately, subjecting the mass to a pressure of approximately 8 to7 5 tons, relieving the pressure and stripping the molded product from acontainer in which it has been subjected to the blow and to thepressure.

8. In a process of manufacturing a building unit, mixing concrete,mixing ammonium stearate and calcium chloride therewith, pouring inplastic form into a mold and subjecting to pressure.

9. In a process of manufacturing a building unit, mixing concrete,mixing ammonium stearate and calcium chloride therewith, pouring inplastic form into a mold and subj ecting to pressure of fromapproximately 8 to 7 5 tons.

10. In a process of manufacturing a building unit, mixing concrete,mixing ammonium stearate and calcium chloride therewith, pouring inplastic form into a mold, striking a blow, and then holding underpressure for an appreciable interval.

11. In a process of manufacturing a bullding unit, mixing concrete,lubricating and waterproofing the mix, acceleratlng the mlx, settlingand distributing the mix by a sudden blow, and forming the mix andcausmg the agents of the mix by heavy sustained pressure.

12. In a process of manufacturing a building unit, mixing concrete,lubricating and waterproofing the mix, accelerating the mix, settlingand distributing the mix by a sudden blow, and forming the mix andcausing the intimate distribution and penetration of the lubricant,waterproofing and accelerating agents of the mix by heavysnstainedpressure, and air drying the resulting product. 1

13. In a process of manufacturing a building unit, mixing concrete,lubricating and waterproofing the mix, accelerating the mix, coloringthe mix, pouring in plastic form into a mold, preliminarily settling anddistributing the mix by a sudden blow while in the mold, and thensubjecting the mix to a relatively heavy and sustained pressure to causedistribution and penetration uniformly throughout the mix and adherenceof the components of the mix for the retention of the form imparted bythemold.

14. In a process of manufacturing a building unit, mixing concrete,lubricating and waterproofing the mix, accelerating the mix, coloringthe mix, pouring in plastic form into a mold, preliminarily settling anddistr1b uting the mix by a sudden blow while in the mold, and thensubjecting the mix to a relatively heavy and sustained pressure to causedistribution and penetration uniformly throughout the mix and adherenceof the components of the mix for the retention of the form imparted bythe mold, and stripping from the mold and air drying.

In testimony whereof, we aflix our signatures.

HOWARD C. BYLAND.

FRANK L. ORMESHER.

